Brush bristle material and brush

ABSTRACT

A brush bristle material comprising a linear metallic material containing powders of one or more kinds of lava abrasive grains and/or basalt abrasive grains in a mixed state at a ratio in the range of 1% to 70%, preferably in the range of 1% to 30%. The powders of the lava abrasive grains and/or the basalt abrasive grains to be included in the linear metallic brush bristle material are incapable of being burnt and melted during the course of the inclusion and capable of enhancing the ability of grinding or abrading. Therefore, it is made possible to optimize the surface treatment of the interior of a hole in a given workpiece and the removal of a burr by grinding and a brush manufactured from the linear metallic brush bristle material.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a brush bristle material that is obtained bycausing a linear metallic material to contain in a mixed state abrasivegrains, such as lava abrasive grains or basalt abrasive grains orpowders thereof, and consequently enabled to optimize the surfacetreatment of the interior of a hole in a workpiece, the removal of aburr by grinding and the like and to a brush made thereof. Thisinvention particularly relates to a brush bristle material that isobtained by causing a linear metallic material, while being manufacturedby melting a metallic material and forming the molten material into awire, to contain in a mixed state lava abrasive grains or basaltabrasive grains or powders thereof and consequently enabled to give aworkpiece such grinding as is suited to hardness, shape and object ofpolishing of the workpiece and relates to a brush made thereof

2. Description of the Prior Art

The brush disclosed in JP-A 2003-164332 is produced by having a metalwire nipped among three metallic wires and twisted in situ. A hollowpipe made of metal is inserted in the twisted part of the brush andfixed in the inserted state by causing the outer periphery thereof to bedrawn.

The brush disclosed in JP-A 2002-254277 is produced by causing anaggregate yarn formed of a plurality of alumina filaments to beimpregnated in a binder resin and eventually cured and bundled. Theplurality of alumina filaments allow the free ends thereof which havenot been cured owing to the adhesion of the binder resin to serve thepurpose of removing a burr, for example, by grinding.

The conventional brush bristle material is such that, when it is made toincrease strength and caused to sustain breakage consequently, thefragments resulting from the breakage will possibly scatter and inducean accident. Further, since the workpieces requiring abrasion areinfinitely varied in hardness, flexibility and shape, the desirabilityof offering brushes that possess characteristic properties capable ofabsorbing this infinite variation has been finding recognition. Themetallic brush bristle materials have encouraged an attempt to enhancetheir abrading or honing capacities by causing metallic materials tocontain in a mixed state diamond abrasive grains or abrading grains orother kinds of abrasive grains. The abrading grains etc., however, areburnt and melted away at elevated temperatures before they are includedin the metallic materials. At times, the conventional brush bristlematerials encounter difficulty in producing brushes endowed withabrading hardness suited to the purpose of grinding.

The present inventors having determined to solve the problem mentionedabove, have discovered that lave abrasive grains or basalt abrasivegrains are capable of being included in a linear metallic material. Thisinvention is aimed at providing a brush bristle material obtained bycausing a linear metallic material to contain in a mixed state lavaabrasive grains or basalt abrasive grains or powders thereof in aprescribed amount and consequently enabled to retain the includedabrasive grains undissolved at an elevated temperature occurring duringthe course of manufacture and also providing a brush made thereof Theinvention is also aimed at providing a brush bristle material obtainedby bundling a plurality of brush bristle materials and subjecting theperimeter of the resultant bundle to a covering or coating treatment,thereby being endowed with proper strength and grinding property suitedto the purpose of grinding without sustaining breakage and alsoproviding a brush made thereof

SUMMARY OF THE INVENTION

The brush bristle material of the first aspect of the invention has alinear metallic brush bristle material contain in a mixed state one ormore kinds of lava abrasive grains and/or basalt abrasive grains at aratio in the range of 1% to 70%.

The brush bristle material of the second aspect of the invention has alinear metallic brush bristle material coated on a partial or entireperimeter thereof with one or more kinds of abrasive grains selectedfrom among inorganic abrasive grains, metal or alloy abrasive grains,volcanic ash abrasive grains, obsidian abrasive grains, lava abrasivegrains and basalt abrasive grains.

The brush bristle material of the third aspect of the invention hasblended and covered

-   -   a brush bristle material obtained by causing a linear metallic        brush bristle material to contain in a mixed state one or more        kinds of lava abrasive grains and/or basalt abrasive grains at a        ratio in the range of 1% to 70%,    -   a brush bristle material obtained by causing a linear metallic        brush bristle material coated on a partial or entire perimeter        thereof with one or more kinds of abrasive grains selected from        among inorganic abrasive grains, metal or alloy abrasive grains,        volcanic ash abrasive grains, obsidian abrasive grains, lava        abrasive grains and basalt abrasive grains, and    -   a synthetic resin material containing animal fibers and/or        vegetable fibers in a mixed state.

The brush bristle material of the fourth aspect of the invention has aplurality of brush bristle materials of the first to third aspects ofthe invention bundled and has the resultant bundle of brush bristlematerial covered on the perimeter thereof.

The brush bristle material of the fifth aspect of the invention has aplurality of different kinds of brush bristle materials of the first tofourth aspects of the invention bundled and has the resultant bundle ofbrush bristle materials covered on the perimeter thereof.

The brush bristle material of the sixth aspect of the invention has aplurality of brush bristle materials of the fourth or fifth aspect ofthe invention bundled and has the resultant bundle of brush bristlematerials covered on the perimeter thereof.

The brush of the seventh aspect of the invention comprises the brushbristle materials of the first to sixth aspects of the inventionsmanufactured into a channel brush, an implanted brush, a welded brushand the like which are fated to serve as a roll brush, a wheel brush, acoiled brush, a tubular brush and a twisted brush.

This invention obtains a metallic brush bristle material by causing alinear metallic material to contain in a mixed state lava abrasivegrains, basalt abrasive grains or powders thereof in a prescribed amountand therefore enables the produced metallic bristle material to acquireproper hardness and grinding property suited to a workpiece, the shapeof the workpiece and the purpose of use of the workpiece.

This invention enables the brush bristle material containing in a mixedstate lava abrasive grains or basalt abrasive grains or powders thereofin a prescribed amount, by subjecting the perimeter of this material toa covering or coating treatment to acquire proper strength and as wellensure prevention of an accident possibly induced when the material isbroken and scattered.

This invention enables combinations severally consisting of varyingkinds of the brush bristle materials to be bundled. This invention alsoenables bundles of brush bristle materials to be further bundled. Thisinvention is thus capable of obtaining such brush bristle materials andbrush bristles as permit proper grinding suited to the property of agiven workpiece.

The above and other objects, characteristic features and advantages ofthe present invention will become apparent to those skilled in the artfrom the description to be given herein below with reference to theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1(a) and FIG. 1(b) depict Example 1 of this invention inperspective views each for illustrating one brush bristle materialhaving a linear metallic material contain lava abrasive grains in amixed state.

FIG. 2(a) and FIG. 2(b) depict Example 2 of this invention, FIG. 2(a)representing the case of having the abrasive grains attached to theperimeter of the linear metallic material and FIG. 2(b) the case ofhaving the abrasive grains attached to the perimeter of the linearmetallic material by a coating treatment.

FIG. 3(a) and FIG. 3(b) depict Example 3 of this invention in aperspective view and a cross section each illustrating the manufactureof a plurality of brush bristle materials by bundling into one brushbristle material.

FIG. 4(a) and FIG. 4(b) depict Example 4 of this invention in crosssections each illustrating the manufacture of a plurality of brushbristle materials by bundling into one brush bristle material and FIG.4(c) and FIG. 4(d) are prospecting views thereof.

FIG. 5(a) and FIG. 5(b) depict Example 5 of this invention in a crosssection and a perspective view each illustrating the manufacture of aplurality of brush bristle materials by covering into one brush bristlematerial.

FIG. 6(a) through FIG. 6(h) are schematic views for illustrating themanufacture of brushes from the brush bristle materials of thisinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The brush bristle material of the first aspect of the invention isobtained by causing one or more kinds of lava abrasive grains and/orbasalt abrasive grains or powders thereof to be included in a ratio inthe range of 1% to 70%, preferably in the range of 1% to 30%, in alinear metallic brush bristle material while the linear brush bristlematerial is being formed by melting iron, copper, aluminum, titanium,nickel, chromium or an alloy thereof. Since the lava abrasive grainsand/or basalt abrasive grains to be included in the linear metallicbrush bristle material are formed inherently at a high temperature, theyare incapable of being burnt and melted during the course of theinclusion but are capable of enabling the produced metallic brushbristle material to acquire an enhanced abrading or grinding ability.

The brush bristle material of the second aspect of the invention isobtained by causing the partial or entire perimeter of a linear metallicbrush bristle material made of iron, copper, aluminum, titanium, nickel,chromium or an alloy thereof for example, to be coated with one or morekinds of abrasive grains, such as diamond abrasive grains, inorganicabrasive grains, metal or alloy abrasive grains, volcanic ash abrasivegrains, lave abrasive grains or basalt abrasive grains. The coating issorted, for example, into electrodeposition, vapor deposition, thermalwelding and plating. This coating is capable of depositing the relevantabrasive grains in a ratio in the range of 1% to 100%. Since the amount(thickness) of this coating can be optionally fixed, it is made possibleto adjust easily the nerve of the produced coat to suit the purpose andthe shape of the coat, enable the synthetic resin material to acquireelastic force, and prevent the metallic material from breakage.Incidentally, the coating at a ratio in the approximate range of 1% to10% on balance is equivalent to a state in which the coat adheres to theperimeter of the metallic material.

The brush bristle material of the third aspect of the invention isobtained as a sole brush bristle material by blending the brush bristlematerial of the first aspect of the invention, the brush bristlematerial of the second aspect of the invention and a synthetic resinmaterial containing animal fibers and/or vegetable fibers in a mixedstate. The synthetic resin material is formed of polyamide-based resin,polypropylene, polyethylene, polyvinyl chloride, polyimide, polymer,polyester, polyplastics, PolyEtherEtherKetone (PEEK™) resin or aromaticpolyamide-based heat-resistant fibers, for example. Particularly, thesynthetic resin material containing in a mixed state animal fibers(horse bristles, pig bristles, etc.) and/or vegetable fibers (pakin(tampico), palm, banana, etc.) is covered so that the brush bristlematerials of the first and second aspects of the invention may bebundled into one piece.

The covering is intended to have a plurality of brush bristle materialscovered with a pipe made of synthetic resin or metal. Otherwise, thecovering is performed by causing a plurality of brush bristle materialsto be either covered with a cord made of metallic wire or syntheticresin and coiled thereon or wrapped in a pouch woven with the cord.

The brush bristle material of the fourth aspect of the invention isobtained at least solely by bundling a plurality of brush bristlematerials of the first to third aspects of the invention and coveringthe collective perimeter of the bundled brush bristle materials. Thebrush bristle material of the fourth aspect of the invention may beobtained as a brush bristle material suited to the surface of a givenworkpiece by properly selecting the raw material of the brush bristlematerial, the number of the materials, and the number of the materialsto be bundled. The covering is implemented by coiling a cord, wrappingwith a net or enveloping with a tube made of metal or synthetic resin,or the like.

The brush bristle material of the fifth aspect of the invention isobtained by bundling a plurality of different kinds of brush bristlematerials selected from among the brush bristle materials of the firstto fourth aspects of the invention. A plurality of the same or differentbrush bristle materials bundled into one piece as described above arebundled and the perimeter of the resultant bundle is covered. The brushbristle material of the fifth aspect of the invention is enabled byoptionally selecting different component brush bristle materials to suita wider range of applications than the brush bristle material of thefourth aspect of the invention.

The brush bristle material of the sixth aspect of the invention isobtained as one or more pieces by bundling a plurality of brush bristlematerials of the fourth and fifth aspects of the invention andsubsequently covering the perimeter of the resultant bundle of brushbristle materials. The brush bristle materials of the fourth and fifthaspects of the invention, for the purpose of acquiring strengthnecessary for grinding a given workpiece, are allowed to select rawmaterials for the brush bristle materials, select materials used forinclusion or application by coating, and decide the number of componentbrush bristle materials to be bundled.

The brush of the seventh aspect of the invention is obtained as achannel brush, an implanted brush, a welded brush or the like by causingthe brush bristle materials of the first to sixth aspects of theinvention to be inserted in a channel member or embedded in a deckmember and straightening the resultant product in shape. The brushes areproperly shaped and finished as a roll brush, a wheel brush, a coiledbrush, a tubular brush and a twisted brush and consequently enabled toacquire such shape, strength and elastic force as are optimized forgrinding a given workpiece.

EXAMPLE 1

FIG. 1(a) and FIG. 1(b) depicts Example 1 of this invention inperspective views each for illustrating one brush bristle materialobtained by causing a linear metallic material to contain lava in amixed state. A brush bristle material 111 shown in FIG. 1(a) has alinear metallic material 11 contain lava abrasive grains 12 or powdersof the lava abrasive grains 12 in a mixed state. A brush bristlematerial 112 shown in FIG. 1(b) has the linear metallic material 11contain lava abrasive grains 12 and basalt abrasive grains 13 or thepowders thereof in a mixed state. The brush bristle material may havethe linear metallic material 11 contain the powders solely of the basaltabrasive grains 13 in a mixed state. The lava abrasive grains 12 etc. orthe powders thereof are included in the linear metallic material 11while this material is kept heated at a high temperature so as to beadjusted to a prescribed diameter. The lava abrasive grains 12 etc. orthe powders thereof are not burnt like diamond abrasive grains becausethey are inherently formed by a high temperature.

The linear metallic material 11 is made of iron, copper, aluminum,nickel, chromium, titanium or an alloy thereof, for example. The presentinventors have discovered that the lava abrasive grains 12 and/or basaltabrasive grains 13 or the powders thereof can be included at a volumeratio in the range of 1% to 70%, preferably in the range of 1% to 30%,in the linear metallic material 11.

EXAMPLE 2

FIG. 2 depicts Example 2 of this invention, FIG. 2(a) illustrating theexample of having the abrasive grains attached to the perimeter of thelinear metallic material and FIG. 2(b) illustrating the example ofhaving the abrasive grains attached to the perimeter of the linearmetallic material by a coating treatment. A brush bristle material 211shown in FIG. 2(a) forms an example of including lava abrasive grains,etc. in the linear metallic material 11 and subsequently attaching tothe perimeter of the metallic material 11 metallic abrasive grains,diamond abrasive grains, grinding abrasive grains, inorganic abrasivegrains, CBN abrasive grains, GC abrasive grains, lava abrasive grains,obsidian abrasive grains, or abrasive grains obtained by mixing them byelectrodeposition, vapor deposition, thermal welding or platingtreatment. A brush bristle material 212 shown in FIG. 2(b) is obtainedby including lava abrasive grains 12 and basal abrasive material 13 orthe powders thereof in the linear metallic material and subsequentlygiving to the perimeter of the metallic material 12 a coating 22 withmetallic abrasive grains, diamond abrasive grains, grinding abrasivegrains, inorganic abrasive grains, CBN abrasive grains, GC-treatedabrasive grains, lava abrasive grains, obsidian abrasive grains orabrasive grains obtained by mixing them. The coating treatment isimplemented by electrodeposition, vapor deposition, thermal welding orplating treatment, similarly to the product of FIG. 2(a).

EXAMPLE 3

FIG. 3(a) and FIG. 3(b) are a perspective view and a cross sectionillustrating the example of forming one brush bristle material bybundling a plurality of brush bristle materials. The brush bristlematerials shown in FIG. 3(a) and FIG. 3(b) are severally obtained bybundling a plurality of brush bristle materials shown in FIG. 1 and/orFIG. 2 into one piece with a cord or a knit cord or the like. A brushbristle material 111 shown in FIG. 3(a) is obtained by including lavaabrasive grains 12 in the linear metallic material 11 and bundling foursuch linear metallic materials into one piece with a cord 31. A brushbristle material 211 shown in FIG. 3(b) is obtained by including lavaabrasive grains 12 in the linear metallic material 11 and depositingabrasive grains on the perimeter of the metallic material 11 by aplating treatment or an electrodepositing treatment. The brush bristlematerials 211 and 212 are severally obtained by including lava abrasivegrains in the linear metallic material 11 and depositing the abrasivegrains on the perimeter of the metallic material by coating. The brushbristle material 211 and brush bristle material 212 are severallycovered into one piece with a cord 31 or a knit cord 32.

EXAMPLE 4

FIG. 4(a) and FIG. 4(b) are cross sections severally depicting one brushbristle material obtained by bundling a plurality of brush bristlematerials and FIG. 4(c) and FIG. 4(d) are perspective views of the samebrush bristle materials. The brush bristle material shown in FIG. 4(a)is obtained by causing the brush bristle material 111 including the lavaabrasive grains, etc. or powders thereof as shown in FIG. 1 and FIG. 2and a synthetic resin material 41 covered, interwoven, or coated withone or more kinds of animal or vegetable fibers to be bundled with acord 411 or a net 412 as shown in FIG. 4(c) or FIG. 4(d). The cord 411or the net 412 mentioned above may be made of any of synthetic resin,natural fibers, and a metal.

Then, the brush bristle material shown in FIG. 4(b) is obtained bycausing the brush bristle material 111 containing the lava abrasivegrains etc. in a mixed state, the brush bristle material 211 havingabrasive grains, etc. attached to the perimeter of the brush bristlematerial 111 by electrodeposition, plating, etc., the brush bristlematerial 212 having abrasive grains applied by coating to the perimeterof the brush bristle material 111, and the synthetic resin material 41covered, interwoven or coated with one or more kinds of animal and plantfibers to be bundled with a cord 411 or a net 412 as shown in FIG. 4(c)or FIG. 4(d).

EXAMPLE 5

FIG. 5(a) and FIG. 5(b) severally depict in a cross section and aperspective view the manufacture of a plurality of brush bristlematerials by covering into one brush bristle material. The brush bristlematerial shown in FIG. 5(a) is obtained as a sole product by inserting aplurality of brush bristle materials 211 and 212 (shown in FIG. 2 andFIG. 3) and 511 in a pipe material 51 made of synthetic resin or thelike. The brush bristle material shown in FIG. 5(b) is obtained as asole product by inserting a plurality of brush bristle materials 211,212 and 511 in a pipe material 52 made of the synthetic resin mentionedabove. The pipe material 52 contains abrading grains, diamond abrasivegrains and the like in a mixed state. Further, the brush bristlematerial allows variation of the kind of raw material, the number ofcomponent brush bristle materials, the combination of different kinds ofbrush bristle materials, and the like.

FIG. 6(a) to FIG. 6(h) are schematic views for illustrating brushes thatare made of the brush bristle materials of this invention. FIG. 6(a)represents a cup brush, FIG. 6(b) a disc brush having a channel brushattached to the periphery of a disc, FIG. 6(c) a disc brush having achannel brush bent in a circular shape, FIG. 6(d) a brush manufacturedby directing inward a brush bristle material attached to a channel, FIG.6(e) and FIG. 6(f) each a roll brush, FIG. 6(g) a tubular brush and FIG.6(h) a twisted brush. These brushes are manufactured fundamentallydependent on the brush bristle materials that conform to the examples ofthis invention.

This invention has been specifically described by reference to examples.The invention nevertheless does not need to be limited to theseexamples. This invention is capable of allowing various alterations ofdesign unless the matters described in the scope of claims for patentare deviated. The raw material of brush bristle, the number of brushbristle materials, the quality of material of the substance to beincluded, the sizes, the shapes and the densities of the relevantmaterials can be optionally selected depending on the kind, the shapeand the purpose of use of a given workpiece. Particularly as regards themetallic member, the synthetic resin member, the member to be includedand the member to be attached, it goes without saying that thosepublicly known or universally known can be used besides thosespecifically cited in the present specification.

1. A brush bristle material having a linear metallic brush bristlematerial contain in a mixed state one or more kinds of lava abrasivegrains and/or basalt abrasive grains at a ratio in a range of 1% to 70%.2. A brush bristle material having a linear metallic brush bristlematerial coated on a partial or entire perimeter thereof with one ormore kinds of abrasive grains selected from among inorganic abrasivegrains, metal or alloy abrasive grains, volcanic ash abrasive grains,obsidian abrasive grains, lava abrasive grains and basalt abrasivegrains.
 3. A brush bristle material having blended and covered: a brushbristle material obtained by causing a linear metallic brush bristlematerial to contain in a mixed state one or more kinds of lava abrasivegrains and/or basalt abrasive grains at a ratio in a range of 1% to 70%;a brush bristle material obtained by causing a linear metallic brushbristle material coated on a partial or entire perimeter thereof withone or more kinds of abrasive grains selected from among inorganicabrasive grains, metal or alloy abrasive grains, volcanic ash abrasivegrains, obsidian abrasive grains, lava abrasive grains and basaltabrasive grains; and a synthetic resin material containing animal fibersand/or vegetable fibers in a mixed state.
 4. A brush bristle materialaccording to any one of claim 1 to claim 3, wherein said brush bristlematerial comprises a plurality of brush bristle materials bundled into abundle and the bundle has a perimeter thereof covered.
 5. A brushbristle material according to any one of claim 1 to claim 4, whereinsaid brush bristle material comprises a plurality of different kinds ofbrush bristle materials bundled into a bundle and the bundle has aperimeter thereof covered.
 6. A brush bristle material according toclaim 4 or claim 5, wherein the plurality of brush bristle materialsbundled are further bundled into a bundle and the bundle has a perimeterthereof covered.
 7. A brush comprising the brush bristle materialaccording to any one of claim 1 to claim 6, wherein the brush bristlematerial is manufactured into a channel brush, an implanted brush, awelded brush which are fated to serve as a roll brush, a wheel brush, acoiled brush, a tubular brush and a twisted brush.